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Outlook XP/2003 printing problems small font size since IE7 update

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I have a customer with a similar problem, and can replicate it.

IE7, Outlook 2003 and Exchange 2003 server (running on SBS 2003)

Some incoming HTML emails will not print the headers at all.

If I convert the HTML mail to plain text (only option) and send it back to myself, the problem disappears; if I then convert the plain text mail to HTML and mail it back to myself, it prints perfectly.

Thus, it has to be either something in the incoming HTML mail or it doesn't happen for the internal domain.

The only clue I have is that the incoming HTML mails might contain extended character sets.

Printing the same emails from Outlook Web Access also shows the same problem - not surprising, because as far as I can tell, Outlook 2003 uses IE for printing of HTML mails (but not Plain or Rich Text). I deduced this a long time ago because if you print an email with a file attachment, plain text and rich text print the file attachment - icon and name, but HTML mails don't (but do from Outlook Express).